Covering for surfaces exposed to the weather



Oct. 5, 1937. s. N. WALLAcE'E-r AL ,0

COVERING FOR SURFACES EXPOSED TO THE WEATHER Filed Feb. 18, 1932asheets-shept 1 INVENTORS 650w: Alwumcf 6 F2070 C/"l'tAM/LEV BY THEIRATTORNEYS Oct. 5, 1937'- e. N. WALLACE ET AL 9 I COVERING FOR SURFACESEXPOSED TO THE WEATHER Filed Feb. 18, 1932 j s Sheets-Sheet 2 G. N.WALLACE Er AL COVERING FOR SURFAOE$ EXPOSED TO WEATHER Oct. 5, 1937.

3" Sheets Filed Feb. 18, 1932 INVENTORS' GEORGE/V. VVALLA c5 c6 HoraCT/YcK/NLEY Q uh R Patented Oct. 1937 PATENT oFFlcE COVERING FOR summonsnxrosnn TO ,THE WEATHER George N. Wallace, New Rochelle, and Floyd C.McKinley, Buffalo, N. Y., asslgnors to Certain- Teed ProductsCorporation, New York, N. Y a corporation of Maryland ApplicationFebruary 18, 1932, Serial No. 593,778

T 10 Claims.

This invention relates to a covering forlaying upon a surface, and moreespecially upon the surf face of-walls, to simulate a structure ofmasonry. The invention relates more particularly to a 5 weatherproofcovering in the form of an element or a sheet intended for laying incomplementary relation to, and preferably in overlapping arrangementwith, similar elements or sheets. Coverings having for their purpose thesimu- "l lation of the surface ofmasonry structures have heretofore beenproposed in the form of strips or sheets upon which have been simulated,by

. grooves or channels in the surface of the sheet or by; cut-outs in theedge of the strip or by combi 5 nations of these expedients, thelongitudinal and transverse Joints'of masonry demarking thema-fIsonryunlts and presenting the appearance of such masonry 'units laid upwith mortar joints Y 'therebetween. We are also aware that it has beenheretofore proposed to simulate the longitudinal joints: of the masonryby forming a channel lengthwise .of a strip of covering material. suchas prepared roofing, at a distance from the edge of the stripcorrespondingrto the depth of the masonry unit, such as the depth of abrick, and cutting out the material of the base of the roofingtransversely of said groovetoform the transverse joints between themasonry units in a, course. Such strips have been provided with a 3'portion adjacent to the groove on. the opposite v side thereof from thesimulated masonry unit,-

which portion is intended to be overlapped by a .similar strip, leavingexposed the groove and the course of simulated masonry units or bricks.

. Moreover, it hasbeen proposed that the surface character. of saidoverlapped portiomshallbe that of the surface of the joints between themasonry units so that'when portions of this overlapped surface are seenthrough the cut-outs in the 40 overlapping strip the character of thesurface of the masonry joints will be simulated not only in thehorizontal or longitudinal joints by the groove but also in the verticalof transverse joints by said surface appearing through the cut-outs.thereby the better to represent the whole character of the surfaceoil-the masonry structure.-

imiilesuch covering "strips, particularly those I made by scraping thegroove or channel above referred to inaccordance with the processproposed by Outman in the Patent uneasy, form a considerable improvementover the units previously sonry units.

the strips upon the wallfand thehandling of a large number of strips, aswell as the fact that the number of'edges which are exposed andsubjected to the action of wind tending to lift said edges from theoverlapping strips is greater than is necessary. Moreover, when sheetsare used which as heretofore proposed simulate a plurality of courses ofmasonry units and when said sheets are cut transversely straight acrossthe simulated courses as has been the'practice heretofore, a longvertical joint is necessary between'the sheets laid endwise toeachother, which joint must cut across at some point one or more of thesimulated ma- The joint is therefore conspicuous and interferes. withand spoils the proper uniformity ofthe simulation of the masonrystructure. Also, in cutting the strips or sheets in the roofing machine,if slippage of the sheet at the cutters shortens slightly the distancebetween cuts and therefore the length of the sheet or ele- Broadly theobject of the present invention,

therefore, is to provide a covering which willproduce the effect ofmasonry, especially of -brlcks laid up in mortar joints.

More specifically the object of the invention is to provide an elementof suitable base material upon. which are simulated, courses of masonryunits with mortar joints therebetween and, in the preferred embodiment,an element having a portion thereof to be overlapped by a similarcovering unit and a portion thereof to be exposed, said portion to beexposed having thereon the simulation of the courses of masonry units,the form and extent of thetw'o portions being in such relation that aweatherproof covering is provided.

In suchcoverings and elements, it is a further object of the inventionto provide the simulation of vertical joints of a plurality of coursesof masonry by cut-outs inthe base in such arrangement that, whilea-weatherproof covering is provided, the character of the mortar'of thevertical joint of the masonry is simulated.

Another object of the invention is to provide an elementinthe'form of asheet having a shape suchjthat; when laid adjacent to similar elementsupon'the'wallto simulat'ea masonry structure the elements will becomplementary to each other while providing for the simulation of themasonry Joints.

.ment, the'joint between the elements is of neces-' 1 A further objectof the invention is to provide a covering element having on the surfacethereof a simulation of a plurality of courses of masonry units withmortar joints. therebetween, which element has a shape such that whenlaid adjacent to a similar element upon thesurface it will form aninconspicuous joint between the elements. A further particular object ofthe invention is to form such an inconspicuous joint between theelements without forming a joint which crosses a simulated masonry unit.

A further object of the invention is to provide an element in sheet formhaving its end edges in stepped shape and with portions of the base ofthe sheet upon which are simulated the mortar joints or portions thereofin certain advantageous relations to the portions of the base upon whichare simulated the masonry units.

An additional object of the invention is to provide a form of elementwhich will avoid the noticeable effect of irregularities in the size ofthe elements when the elements are laid in adjacent relation upon asurface.

A further object of the invention is to provide a method of manufactureof such elements in sheet form by which said elements may be producedcontinuously with a minimum waste of material and without trimming orother extra operations.

The invention, therefore, broadly comprises the provision of a sheet oran element of covering material uponthe surface of which are simulatedmasonry units laid in a plurality of courses with mortar jointstherebetween, said joints extending generally longitudinally andtransversely of the courses as is usual in masonry structures. In onephase of the invention the sheet or element is cut or otherwise formedso that in general the edges of the sheet or element are coincident withor extend within the area of the simulated longitudinal or transversejoints of the masonry. In general, also, particularly in such masonrystructures as brickwork, the longitudinal edges of the sheet or elementmay coincide with or lie within the simulated longitudinal joint of themasonry or brickwork; The transverse edges of the element may similarlycoincide with or lie within the vertical joints of the masonry. It willbe understood, particularly from .the more detailed description tofollow, that in the simulation of usual masonry structures, especiallybrickwork, due to the offset arrangement of the vertical joints of thestructure the end edges of the sheet or element will be in "stepped formbecause of cutting or forming these edges of the sheet or element alongthe linesof the vertical joints and also ialong the lines of thehorizontal joints connecting the vertical joints at the ends of thosemasonry units which are positioned at the ends of the courses simulatedupon the sheet or element.

Upon the surface of such a sheet or element there will always beprovideda full representation of the masonry unit and the edges of thesheet will at no place out across the masonry unit. Inasmuch as theexposed areas of the masonry units are much greater than the exposedareas of the masonry joints, the edges of the sheet or element and thejoints beween two elements from the" simulation ofthe masonry joint,especially in certain embodiments of the invention to be hereafter moreparticularly described, and

in the cutting-of the sheet in the manufacture thereof, which has beenreferred to above, will be less noticeable when the joints between theelements are made along the lines of the simulated masonry joints, ashas been set forth above. Any variation in the width of the jointbetweenthe elements when they are properly alined relative to each otherto simulate. the masonry will not detract from the uniform appearance ofthe masonry units andof the masonry structure simulated upon the elementas only a slightly thicker mortar joint is produced. Such variations ofjoint thickness frequently occur in actual brick work while thealinementof the joints is maintained.

The stepped form provides certain other features of the invention,including the proper spacing of the elements when laid adjacent to eachother and also provides marks for laying'the elements in the courses inoverlapping arrangement. Moreover,an extension of the stepped form,especially in the elements whichare arranged in overlapping arrangementin courses, particularly in the embodiment of the invention whichutilizes cut-outs to simulate the transverse or vertical joints of themasonry or brick- The sheets or elements of our invention may beproduced by a simple, continuous method with out unnecessary waste ofmaterial and by the formation of simple short cuts, especially thelongitudinal cuts, as will.be hereafterv described,

which not only may produce the stepped form but also may complete thesevering'of' the indi! vidual sheet or element from the ,Sheet materialfrom which it isvmade.

Other features of the invention will be understood from a considerationof the following description when taken in connection with the ac- Icompanying drawings in which:

Fig. 1 shows an assembly upon a surface to be covered of elementsembodying the features of the invention; A

Fig. 2 is a face view of one of said elements; Fig. 3 is a section takenon line 3-3 of Fig. 2; Fig. 4 shows a modified form of the element; Fig.5 shows the end of an element of modified form complementary to thatshown in Fig. 4;

Fig. 6 shows'a. sheet from which said elements -may be-produced andillustrates the steps in the process of producing said elements;

Fig. 7 is a diagrammatic cross section of a cutting roll over which thesheet illustrated in Fig. 6

is passed and in one of its positions in the cutting Y of the sheet online AA of Fig. 6;

Fig. 8 is a face view of a single element of said modified form; and

Fig. 9 is an assembly'of another modified form of the covering elementof the invention.

In Figs. 1 and 2 is shown one embodiment of the invention to simulatebrickwork in which courses of bricks are laid in the so-called stretcherarrangement, that is, with the bricks laid flat lengthwise of the'course, the exposed face of the brick being'th'at presented by thelength of the brick and the thickness thereof.

The bricks are laid in each course separated by mortar joints and thecourses are separated by layers of mortar, the mortar of the jointsseparating the bricks in the courses usually in actual brickworkconstruction being pointed up to insure the complete filling of thespace between the bricks and the continuity and joining of thehorizontal and vertical joints. In the so-called "stretcher arrangement,the bricks all being of header construction of brickwork, as well asother types-such as the Flemish bond, headers on end, and other wellknown types of brickwork in which in general the vertical joint in onecourse is offset a distance from a vertical joint in an adjacent courseabove or below.

Moreover, the invention is applicable to the simulation of masonryconstruction utilizing other masonry units, such as stone of regular orirregular size alone or in combination with brickwork in which there areJoints between the masonry units extending generally longitudinally orhorizontally of the construction and also joints between the masonryunits transverse to said ion.- gitudinal joints. In the simulation ofsuch constructions according to the invention a sheet of coveringmaterial preferably of a felt base impregnated with asphalt or otherwaterproofing material such as is commonly, used in the manufacture ofroofing and roofing strips or units may be utilized. Upon the face ofsaid sheet or element there is provided a simulation of the masonryunits with their longitudinal and transverse mortar joints. While theinvention in certain features thereof may be applied to coveringelementswhich are merely laid adjacent to each other without overlappingone element or one row of elementsupon another, especially when thecovering material is not subjected to the weather, there may also beprovided according to the invention such overlapping arrangei a sheet ofroofing material having a portion comprising a base upon the surface ofwhich are formed stripes 2 extending lengthwise of the .element andparallel to the lengthwise edge thereof.- The stripes '2 areseparatedfrom each other and from'the lengthwise edge of the sheet distancesequivalent to the depth of a brick when laid flat in a course of bricksin the usual manner to produce the so-called "stretcher construction.There are thus demarked upon the portion of the surface of the elementto be exposed areas which, when suitably divided to simulate vertical.joints of brickwork, will. represent bricks 3 with joints I therebetweenlaid in courses with the a vertical joints 4 in the staggeredarrangement of there is provided a portion I of a width preferablygreater than that of the exposed portion and having a character ofsurface to simulate the character of the mortar in the joints of thebrickwork. Preferably the height of this portion 5 ina directiontransverse to the longitudinal or horizontal joints of the brickwork isgreater than the sum of the depths of the bricks in the courses with ajoint for each course. In the embodiment shown in Figs. 1 and 2 thisheight is greater than the depth of the three brick courses with the twohorizontal joints therebetween and including the width of a joint abovethe uppermost of the three courses of brick'. In other words, the heightofthe' portioniv exceeds three times the depth of a brick plus thethickness or width of a mortar Joint.

To provide for the so-called "head lap which is customarily used inoverlapping arrangements of covering units the height of the-portions Ishouldfurther exceed that of the exposed portion by an amount equivalentto this "head lap.-

It will be clear from the figures that in the element illustrated inFig. 2 and in the assembly of such elements in Fig. 1 this "head lap"has been provided for whileleaving exposed a portion of the area isubjacent to the lower edge of an overlapping element, saidexposed-portion of the area 5 being of a widthrin the vertical directionequal to the thickness-of a mortar joint. Thus in the assembly of theelements upon the surface to be covered thereis provided the simulationof the longitudinal or horizontal jointsof the masonry or brickwork byleaving uncovered a portion of the area 5 while at the same timeproviding for the desired head lap".

If desired, marks may be placed upon the por-' tion 5 of the element toprovide a gauge for vertically spacing the lower edge of a superimposedelement from the upper edge of the uppermost bricks of the three coursesof brick. Such a laying mark or gauge may be provided by a longitudinalline upon the area 5 parallel to the courses of the brickwork and ata'distance above the upper edge of the uppermost course substantiallyequal to the thickness of a horizontal joint of the brickwork. The loweredge of a superimsimulation of horizontal masonry joint above said 50uppermost course of bricks and below the lowermost course of bricks uponthe superimposed element. It will be seen that thereby the two elementswill be properly spaced and that a repetition of such gauging in theother elements upon the surface to be covered will produce an' orderlyand uniform arrangement of the elements upon said surface. It will beunderstood, however, from a study of Fig. 1 that a gauge mark may beplaced upon the area 5 so thatthere may be laid in register therewiththe upper edges 8' v of the element or the edge It of the element.Similarly a laying mark may be-placed upon the area 5 of thesuperimposed element at the edges it so as to register with the upperedge of'the Other posiis accomplished by cuts through the base of the 4sheet at 4, through which cuts may be seen the surface of the area 5upon which is overlapped the exposed portion of the element in whichsaid simulation of the vertical joints of the brickwork cuts are formed.Thus by suitably providing the cut-out of about inch is found to producethe surface of the mortar joint and similarly providing the area 5 witha surface of saidcharacter, there is simulated for all of the jointsequal to the depth of the masonry unit or brick.

The cut-outs 4 formed in the lengthwise edge of the sheet or elementextend from the lower side of the first horizontal stripe to saidlengthwise edge of the sheet and thecut-outs 4 in the third course ofbricks upon the sheet extend from the upper side of the second stripe tothe lower boundary of the area 5 described above. The cut-outs'in thesecond course are shown extending between the two stripes. However, thecuts 4 may be made of greater or less length within such limits as willprovide a proper simulation of the transverse or vertical joint insuitable combination with the simulation of the longitudinal orhorizontal joint of the masonry or brickwork, and the invention is notlimited to the particular extent and/or position of the cut-outs 4 inrelation to each other nor to the,

simulation of the longitudinal joints as shown in the figures. Inpractice it is found desirable to make the length of the cut-outsslightly longer than the depth of. the masonry unit in order to assureremoval of the slate between the horizontal stripes. An extra length ateach end of good results.

As shown in Fig. 2, the end of the element is cut inja stepped or'oifsetshape. In the preferred embodiment of the invention this stepped shapeis of the same .or complementary form at the two ends of the elements.As illustrated in Fig. 2, the right hand end of the elements is of thesame form as the left hand except asmodified by the cut-outs 4 or thespaces equivalent to these cutouts provided at the ends of each courseof the bricks. As illustrated, the transverse cuts through the sheetsare coincident with the end edges of the bricks at both ends of thethree courses simulated upon the portion of the sheet to be exposed andsaid transverse cuts are continued across the simulated horizontaljoints of the brickwork which are subjacent to the courses. Thelongitudinal or horizontal edges of the stepped form of the ends of thesheet as illustrated are out along the upper edges 8 of the end bricksof the two lower courses or, what is equivalent. are out along thebottom lines I] of the longitudinal joint lying above said two lowercourses.

' It will be noted-however, that a short longitudinal edge I0 ,isformed. on the upper side of said two simulated longitudinal joints atthe right hand end of the element coincident with the lower end edge ofthe cut-out at said right hand end of the second and third courses. Thusit will be clear that in the particular embodiment being describedexcept for the longitudinal cuts ill and the cuts 9 transversely of thelongitudinal joints the stepped form of the exposed portion ofthe sheetis made by transverse and longitudinal cuts along the edges ofthe'bricks. Moreover, it will be noted that the portion l I of the twosimulated longitudinal joints which depend from the left hand end ofbricks 3 of the second and third courses of bricks are formed by a cutcorrespondingly exactly to the cuts 8 mentioned above which aremade'along the upper edge of the two lower courses of brick at the righthand end of the the portion of the base cut away by the cut.-'

outs 4 at 'the'ends of the sheetthe ends of the exposed portion of thesheet are exactly complementary. As will be further described inconnection with Figs. 6 and '7, these longitudinal cuts, therefore, maybe made at the same time and simultaneously with. severing the elementfrom the sheet.

It will be noted that the position of the transverse cuts 9 has beenselected in the form of element illustrated in Fig. 2 so as to coincidewith the right hand side of the vertical joint simulating spaces orcut-outs 4 at said end of the sheet. While this is an advantageousposition for these cuts 9, they need notbe limited to this position andmay be made at any point between the position shown which is coincidentwith the right hand edge of a space 4 and the left hand edge of such, aspace, longitudinal cuts 8 being suitably extended to meet and intersectthe cuts 9. However, it will be noted that if the cut 9 at the righthand edge is moved to the left and if said out produces also, in asucceeding element as cut from a sheet of roofing, the corresponding endedge of the portion of the horizontal joint as shown at H, such portionll would have a piece '9 and I0 is preferably equal to the width of thecut-out's4 and the height of said step is equal to the width of thehorizontal joint.

The steps formed by the edges 9 and I0, therefore, provide an abutmentagainst which may abut the end of the portion ll of the horizontal jointat the left hand of a similar element when laid adjacent to the righthand end of the first element. Thus there is insured a proper spacingfor'the second and third courses of the adjacent element relative to thefirst. element so as to insure the equivalent of the space or cut-out 4being formed by the joint between two elements laid endwise to eachother. Moreover, in view or the steppedform' of the sheet and of the twoabutments formed by the edges 9 and Ill, spacing is also providedbetween the end bricks oi the lowest or first course of bricks upon thetwo sheets. This will be clear from the above description taken inconnection with Figs. 1 and 2. It also will be noted that the length ofthe simulated horizontal joints 2 is as much greater than the -length ofeach of the three courses of brick as the width of a vertical joint.This is true whether ornot the transverse edge 9 is cut at the righthand or at the left hand edge of the cutouts 4 or at a pointtherebetween as described above. Thus there is provided in the sheet orelement itself a gauge for laying the sheets endwise to each. other toproduce a proper spacing of the elements in a direction lengthwise ofthe courses of masonry or brickwork to insure a uniformity of verticaljoint simulation and to provide an inconspicuous joint where one sheetabuts or lies endwise to another.

It will be noted that the combination of the cut-out for simulation ofthe vertical joint with the use of the short transverse cuts across thesimulated horizontal joints but avoiding cuts ace-aces across the bricksimulating'areas, as afforded by L simulate the masonry units or bricksmay be so the stepped shape of the ends of the sheet, contributes tomake inconspicuous and unnoticeable the joint across the exposed portionof the covering. Moreover, the longitudinal cuts 8 extending in the sameor generally same direction as the longitudinal joints of the masonryare not readily seen because they do not arrest the eye in any mannerdifferent from that of the simulated longitudinal joints. 1

While we-have shown in the embodiment illustrated in Figs. 1 and 2cut-outs in the body of the sheet to represent the intermediate verticaljoints of the brickwork, our invention is not limited to the use ofcut-outs for simulationof these.

intermediate joints. which simulation may be provided in any convenientway to properly accomplish in combination with the simulation of thelongitudinal joints the desired representationof the masonry orbrickwork. Moreover, we may also substitute for the portions 4, cut outat the endof the sheet to simulate the vertical joints-between bricks atsaid ends of the sheet, a simulation of the same type as that adoptedfor the body of the sheet. In such case if no material of the body ofthe base of the sheet is removed to form these simulations, thelongitudinal cuts 8 in combination with transverse cuts along saidvertical joints nevertheless provide and make possible the steppedarrangement with the advantages described above as to forming theinconspicuous joint. It will be clear also that if no material of thebase is removed,

I jacent to another element endwise thereof. .The

dot and dash line's shown in this figure illustrate the position of theelement I when laid in said adjacent position upon the surface to becovered. It'will be'seen that the edges of the portion II, when thesheet is in position, coincide with and fit against the upper edges 8 ofthe two end bricks 'of the two lower courses simulated at the right handof the adjacent element at the left. It will also be seen that the endsI2 of the three brick courses of the lifted element will fall intopositions which are spaced from the right hand ends of the end bricks ofthe three courses upon the adjacent element at distances therefrom equalto the width of the vertical joints. Moreover, it

will be clear that the element I when folded down into position againstthe adjacent element is spaced therefrom by the abutments formed by theedges 8 and III as above described.

It will also be apparent from a study of Fig. 1 that when the element Iis folded down and abutted against the element adjacent endwise theretothe joint betweenthe exposed portions of the two elements falls upon theoverlapped portion I of a subjacent element upon whichsaid folded downelement and its adjacent element are lapped. Said joint made in thestepped arrangement of the present invention may-be so locatedlongitudinally of the courses of masonry, i., e.,

lengthwise of the elements with respect to simi-' lar joints betweenelements, that the two joints are not superimposed. The vertical jointssimulated by the spaces betweenthe areas -3 which covering is prevented.

positioned, and in the brickwork simulation will be so positioned. as tocarry out the staggered arrangement of the vertical joints of masonry orof brickwork. In general the joint between two adjacent elementsincluding the spaces or cutouts at the ends of said elements, therefore,must lie superimposed upon a portionof the 'area 8, thereby. providing awater tight covering, the

1 area 5 underlying the joint being continuous.

When the sheet or element is provided with a suitable head lap asdescribed above, the. passage of any water which may enter the jointover said area 5 and outfromunder the overlappin elements is thusinsured and leakage through the Also, any water entering through thecut-outs used for simulation of the vertical joints in the body of theelement passes over the area 5- and out from under the element.

In order to guard against the possibilitythat the joint between twoadjacent elements may fall upon the joint between two adjacent areas 5in two subjacent elements l'aid adjacent to each other, in anotherfeature of our invention we have provided the area 5 with an end edge instepped shape, that is, having its edge offset in relation to the endedges of the exposed portion. In forming the step or offset for the area5 as v shown in Figs. 1 and 2, we have formed a transverse. edge I5extending across the main portion of the area 5 to meet a longitudinaledge It of said area I, which edge I8 connects said transverse edge I6to a transverse edge or cut 4 upon the exposed portion of the sheet. Inorderto prevent the joint between two exposed portions of adjacentelements overlappingupon said area I from falling in superimposedposition upon said transverse edge I5 of the area 5, we preferably formthe edge I5 of said area 6 at a point or on a line which will liebetween transverse or vertical joints of the masonry or brickwork attheends thereof'. In the embodiment shown in Figs. -1 and 2 the transverseedge I5 is formed on. a line which, if extended, will pass betweenbrickwork. This position for the edge IS in the brickwork constructionillustrated insures said edge lying underneath a part of the exposedportion of an overlapping element in which there is no cut-outforsimulation of a vertical joint nor a cut to form the end of saidelement. .The reason for this will be evident from a study of theflguressince in the brickwork construction which is simulated the regularity ofofl'setting of the vertical joints insures that no end edge of anelement or sheet-will coincide with an overlying cut-out because'theoffset or stagger of the vertical joints is always equal to one-half thelength of. the brick whereas the offset provided by the edge I5 is lessthan one-half of a brick. Howwhether simulated in the body of theelement or v two vertical joints 4 in. adjacent rows of the I ever, inother modifications of the invention the edge I! while in steppedrelation to the end edge of the exposed portion may be positioned insuch relation to the said end edges of the exposed portion 0'!theelement and to any cut-outs there.-

in that it will lie under a solid portion of thebody of the sheet, thatis, a portion having no cut-outs therein which are in linewith the edgeI5 whether or not the stagger of the vertical joints'as simulated isregular or irregular.

than the width of a horizontal joint. Thus when an overlapping elementis laid with its exposed edge a distance above said top course of bricksequal to the width of a horizontal joint, the longitudinal edge I6, asmay be seen in Fig. 1, will be covered by the lower edge of saidoverlapping unit. It will be plain from the explanation just given inregard to therelation of the edge l5 of the overlapped portion to theend edges of the .exposed portion and to the cut-outs simulating thevertical joints that the edge IE will also fall under a solid portion ofthe sheet. Thus there is insured a greater protection against seepage ofwater through the joint in the overlapped portion and assistance isgiven to the means used for holding the sheets in position upon thesurface by having the corner I8 caught underneath said bottom edge ofthe exposed portion of the overlapping element. I

The edge l9 at the left hand of the element 1 in the illustratedembodiment of the invention is also cut longitudinally at a distanceabove the top of the top course of bricks greater than the width of ajoint. Preferably in the manner to be described in connection with Figs.6 and 7 as mentioned above, the edge l9 and the edge l6 are cutsimultaneously and the edge IQ of the lifted element, which, as shown inFig. 1, when folded down lies adjacent to a similar element upon thesurface, coincides with and abuts against the edgel6 of said adjacentelement. Also the edge 20 may be cut at the same time as the edge l5 ofan adjacent unit and when the element is folded down said edge 20 willabut the edge l5 of an adjacent element upon 'the surface to be covered.Thus it will be seen that the form of the end edges of the portion ofthe element to be overlapped are also of complementary form at one endof the sheet relative to the other end thereof. Moreover, the abutmentof the edge 20 against the edge l5 assists in carrying out the spacingof the elements one relative to the other to insure the simulation ofthe vertical joints of the masonry or brickwork in a manner similar tothat described in connection with the abutments formed by the edges 9and Mas described above. It will be understood from the explanationgiven above in connection with the abutments 9 and I and the portions IIthat similarly the length of the area between the edges l5 and 20 may beas much greater than the length of the courses of brick simulated uponthe element as the width of thevertical joint. Also the length of saidarea 5 and the length of the portions of the element upon which aresimulated the horizontal joints between the courses of brick may be thesame, thus insuring not only the proper spacing as described above,between the elements, but proper alinement and squaring of the elementsto insure alinement of. the courses of bricks so as to carry out arealistic simulation of the brickwork construction.

A modification of the element may be made so as to utilize the edges l6and I!) as -laying marks for spacing and alinement of the element. Theedge I6 may be cut at "such a distance from the upper edge of theuppercourse of bricks simulated upon the element that, when the lower edge ofsaid element is separated from a similar upper edge of the upper courseof bricks upon an underlying element by the space necessary to providethe simulation of the horizontal 'joint'of brickwork as has beendescribed above, said edge I6 of the overlying element will coincidewith the upper edge of the area 5 of Said underlying sheet.

element. The element to besuperimposed, therefore, may be laid byregistering said edge IS with said upper edge of thearea 5' of theunderlying element. Similarly the edge ,IS'may be brought into registerwith said upper edge of the underlying element if said edge I9 is at theproper distance from the. upper edge of the upp rmost course of brickssimulated upon the element. In forming complementary elements said edgel9 would be formed at such distance when edge I6- is formed as will behereafter described.

While in the embodiment illustrated in and 2 we have shown the steppedor offset arrangement at one end .complementary to the other end withthe stepped shape rising in the same direction, that is, toward the leftend of the sheet as shown in the figures, nevertheless it is within thescope of our invention to provide this stepped or offset shape or formwith the steps in opposite directions as shown in Fig. 4.Complementary-elements may be made by forming alternate elements withstepped edges in reverse The-sheet as indicated in Fig. 4 has the stepsprogressing toward the center ofits directions.

length as they rise from the bottom edge of the Upon the elementcomplementary thereto as shown in Fig. 5, the stepped formof edge may beprovidedfwith the right hand stepped edge of the complementary sheetdiverging from the center of the length, the left band edge (not shown)diverging in the opposite direction. The functions performed by thevarious parts of the stepped form and portions of the sheet to simulatethe joints and to provide'the spaced relation of the elements and toproduce a covering which will be weatherproof and water tight will bethe same as those of the element described in connection with Figs. 1and 2. Other modifications are also possible within the spirit of theinvention.

In Fig. 6 is shown a sheet from which an element such as is illustratedin Fig. 2 may be cut by a continuous operation. This figure also il--lustrates the method of producing a sheet the ends of which are ofcomplementary form and as well shows the method of producing a sheethaving the cut-outs to simulate the vertical joints. From a roll of.sheet roofing or from any other supply, sheet 25 may be delivered so asto be fed over a cutting roll in the direction of the arrow as showndiagrammatically in Fig. '7. The sheet as fed to the roll may beconveniently of the width required to provide a surface upon which maybe represented, in the case illustrated, three courses of bricks withtwo longitudinal joints therebetween and including a portion of theelement intended to be overlapped as represented by thearea 5 describedin connection with Fig. 2, said area 5 allowing also for a longitudinaljoint above the uppermost course of brick .as well as for a head lapat'the upper edge of the overlapped portion.

By suitable means not shown and which form no part of the presentinvention, stripes may be formed upon the sheet either inra previousproc-' Figs. l

I the surface thereof, sometimes with the assistance of a fine dust of.slate' thereon, is usually of a character to prevent the adhesion ofthe granular slatemate'rial used for surfacing thesheet, said granularmaterial adhering. however,

- to the portions between the grooves. This,

granular slate or other granular material may be chosen so as to presentupon the finished element the surface character of a masonryunit,

such as a brick in different colors and size of 15 grain to simulatedifferent finishes of the ma:

sonry unit.

The area 5 also may be scraped by the method of the Outman process toproduce a surface to which the granular material simulating the sur- 20face of the masonry unit will not adhere: Moreover, upon the surface 5and the grooves'2 may be applied in any suitable manner a surfacingmaterial which will have the character or appearance of the surface ofthe mortar of the mortar 25 joints of masonry or brickwork. Theapplicationof these materials, whether of the slate for surfacing thearea simulating the masonry units,

or the bricks or for surfacing the area 5 and the grooves 2, may beapplied subsequently to the 30 scraping of the grooves and the area 5,and advantageously the application of the material to simulate themortar joints may be made prior to the application of the surfacingmaterial to simulatethe masonry units, thus serving the double 5 use ofpreventing the-adhesion of the granular material or slate simulating themasonry'units to those portions which are intended to simulate themortar joint. However, the stripes may be made in any suitable-manner tosimulate the '40 longitudinal Joints of masonry, and one other .methodof producing a stripe is shown in the patent to Overbury 1,154,334. Thearea 5 also may beproduced by the application of a granular material ofdifferent character than that of the 45 granular material used tosurface the area and "-simulating the masonry units without scraping thesurface in accordance withthe method of Outman which method, however, weconsider preferable for producing both the area 5 and the 7 5osimulation-oi the longitudinal joints 2. t

' By whatever method the sheet 25 is preparedfor delivery to the cuttingroll 26, according to the particular method disclosed in Figs. 6 and '7we deliver to this cutting roll a sheet having 55 longitudinally thereonstripes 2 to simulate the longitudinal joints of the masonry anddemarking the areas 21 which in the finished elementwill present thesimulation of the exposed surface of the masonry units. Preferably, as

- 60 above described, the sheet also has an area 5 in-- tended to beoverlapped in the finished element. In so far as the method of producingthe element of the present invention broadly is concerned,

this .area 5 may or may not be provided for' in 5 the sheet as it is fedto the cutting roll.

The position of the cutting roll is represented in Fig. 6, by the line1-1 which may be considered to be the axis of the cutting roll 26. As-

shown in Fig. 6, an element I has been cut from 7 the sheet upon theline A-A. The end edge of the sheet which has already passed under thecutting 'roll is formed in the stepped form with corners at 3|l,-3l, 32,33, 34,35, 36, 31, 38, 39 and 43. It will also be clear from Figs. 6 and'7 that 75 the 'edge A-A has passed under the cutting roll aresuccessively made the cuts in the sheet producing the cut-outs 40, 4|,4:, 4s and is before the cuts which bring about the severing of theelement from. the sheet are started. After-the cut-out 44 is finishedthe sheet passing over the revolving roll 26 reaches a point over thecutter which is 'on the line 30-3l; Upon the roll 26 the cutting edgesare so' arranged that as the sheet passes thereunder continuously andconsecutively the edges 3l-32, 32-33 will be cut.

The edge 32-33 meets the cut-out 4 (45) which is next formed by afurther fractional 'revolution of the roll 26. As the right band edge ofthe cut-out 4 (45) is formed the edge 34-35 is cut and with furtherturning of the roll 26 the longitudinal-edge 35-36 is cut. Upon reachingthe point 36 there will also have been out another cut-out 4 (46), andwhen the cutting roll has reached the point 36 the transverse edge 31-38will be out. By further turning, the longitudinal edge 38-39 will be cutand upon reaching the point 39 there will have been cut the cut-out- 4(41) which intersects the edge of the sheet 25.

At the time of cutting thecutut'4 (41) at the edge of the sheet 25 therewill also have been cut the cut-out 4 (41) in line therewith in thesecond course removed therefrom above the sheet, that is, the thirdsimulated course of bricks. Thus it .will be seen that'upon the end ofthe sheet 25, the sheet having passed under the roll from the end edge30-3! to the end edge 33-49, the stepped form of the sheet which hasbeen described will have been made and the staggered vertical joints ofthe brickwork of the end bricks of the three courses ,will have beenproduced. By further turnin 'gof the roll 26 and delivery of the sheetthereunder, the cuts 40, u,.

42, 43 and 44' will be made in the body of the sheet or intersecting theedge of the sheet as the' case may be, as above mentioned. The cuts 43.45

these cuts are not yet formedin the sheet as the sheet has not yetpassed underthe roll 26 placed at line I. When the sheet has passed theposition of the cut-out 44 and intermediate said cut-out 44 and thecut-outs 45, the severing cut 30-3l will be repeated and the separationof the element from the main portion of the sheet being delivered to theroll willbe started. The subsequent steps for cutting the edges 3l-32,32-33 and the successive cuts to produce thecut-outs 4 and the stepped,edges ofv the sheet, as has been described, will be repeated. 7

Thus it will be seen that the process of producing the element 1 of ourinventionmay be continuous and may be carried out without waste of anyof the material of the sheet 25 except that removed in forming thecut-outs. '4. If the representation of the vertical joints of thebrickwork or of the masonry upon the surface of the sheet isaccomplished by other means,even\ such waste is avoided and all thematerial of thesheet 25 is utilized to produce the element L, It willalso be clear from the description given above and from Figs. 6 and 7,that when cut-outs are -provided in the sheet the severing of theelement from the sheet is accomplished substantially by longitudinalcuts connecting said cut-outs. In some cases, as in the formillustrated, the short transverse cuts'32-33, 34-35, 31-38 are used toconnect respectively the longitudinal cuts 3l-32, 35-36, 38-39 with thecut-outs 4. However, our invention is not limited to the use of theshort transverse cuts 32-33, 34-35, 31-38, and as will now be apparent,we may connect the edge 30-3l with the cut-out 4 at position 45 by a outwhich would slope from the corner 3i to the corner 33 and similarly thelongitudinal cut 35-36 may be made from the corner 34 to a corner of thecutout 4 at position 46. Moreover, while we have shown the cut-outs 4extending between the stripes 2 and of a length equal to the end edge ofa brick, it is within the-scope of .vour invention that the cut-outs 4shall be made of such lengths as to span the depth of a brick plus thedepth or width of one or more mortar joints. Thus it will be clear thatthe longitudinal cuts made for severing the sheet and for producing thestepped form of the end of the sheet may be made without the assistanceof transverse cuts such as 32-33,

34-35, 31-38 to connect the longitudinal cuts with the cut-outs, andthat the longitudinal'cut may be made along any line within the width ofa longitudinal joint of the masonry to connect the cut-outs with eachother or with the end edge of the sheet. In thus cutting the sheet andforming the cut-outs 4 at the positions 45 and 46 the outs 3l-32 and32-33 produce the edges J6 and I9 as shown in Fig. 2'and also theabutment l3 adjacent the edge IS. The cuts 34-35 and 31-38 produce theabutmehts shown and described in Fig. 2 in connection with the edges 9and N. If the longitudinal cuts' are made without these transverse cuts,as has been described, as for example by a diagonal cut from the corner3| to the corner 33, reliance may be placed upon the abutment of theedges 20 and i5 as shown in Fig. 1 which are produced by the transversesevering cut 30-3! for proper spacing of the -,units to simulate thevertical joints or thesheets may be spaced by laying marks upon the area5 or elsewhere upon the element. However, such a diagonal cut, since nomaterial is removed from the sheet, may also produce complementaryoutvlines upon the two elements which will fit together and assist inmaintaining the spacing and proper relation of adjacent elements.Moreover, such a diagonal cut would serve such a purpose if instead ofthe cut-outs other means were used for simulating the vertical joints.It also will be understood that if said vertical joints are simulatedwithout the cut-outs, nevertheless the 1st ped form of the end of thesheet may be produ edby the severing of the sheet by successivetransverse and longitudinal cuts and also that in this mannercomplementary elements may be produced.

. The method and steps which have been described in connection withFigs. 6 and 7 for producing the elements having the stepped shape of theend of the element may be utilized to produce the form of element shownin Figs. 4 and 5.

. In addition to the cutting edges which produce i simulation of thelongitudinal and vertical joints the 'end edge A-A of the, sheetit willbe necessary to mount upon the roll 26 a set of cutting edges in reversearrangement to the first mentioned set so that first a severing cut willbe made and these figures as well as the other figures of the drawingstaken in connection with the explanatlon given will make clear that thestepped or oflset form of the end of the sheet may be produced invarious ways and that the elements may be provided with complementaryends without wastage of material and with a simple and continuousprocess of manufacture, and that elements of this type will makepossible the covering of a surface, such as a wall, with a covering theJ'oints between the elements of which are not conspicuous and do notdetract from the appearance of the covering and from the simulation ofthe masonry construction. By our invention when such elements are laidin overlapping arra'hgement, a water tight construction of the coveringis provided while maintaining as to appearance the advantages which areafforded by the stepped arrangement of the joint between the elements.

Although we have described this method of continuous cutting of thesheet for severing the element therefrom in the stepped form as a method.of producing elements to simulate brickceeds and the steps utilized areequally applicable to the production of elements which may simulateother types of masonry construction. When the simulation of suchstructures provides for longitudinal joints of greater'or less extentand transverse joints intersecting or meeting said longitudinal joints,there is provided the opportunity to cut the sheet in stepped form inorder to obtain the edges which have been described in connection withFigs. 1 and 2.

If desired, the sheet as it is delivered to the cutting roll 26 maybeprovided without-outs 4 previously cut therein and suitably combined andcooperating with longitudinal stripes on the sheet to simulate themasonry structure and the severing of the sheet may be accomplishedmerely by making the longitudinal cuts connecting the cut-outs. If noarea 5 to be overlapped is provided upon the sheet, then thelongitudinal cuts will suflice to sever completely the element from thesheet and to produce the stepped form. However, we prefer, as has beendescribed above, to form the cut-outs successively and in a continuousoperation with the making of the severstruction of the element whilemaintaining the form embodying the features of the invention asdescribed in connection with Figs. land 2. In the form shown in Fig. 8the longitudinal joints 2 may be simulated in the manner described inconnection with Fig. 2 or in any other desired manner, and also thesimulation of the vertical joints may-be provided by the cut-outs 4,which cut-outs,- to provide the simulation desired in this embodiment,are of greater or less length in'conformance with the depth of themasonry units between which they are placed. For example, the largemasonry units 50 as shown are of such depth as to cover the depth of twocourses of brickwork'and the cut-outs 5| in the body of the sheet extendalong the vertical edges of these units. At the left of the elements 50is shown, by way of variation of the structure, a unit 52 which may, forexample, correspond in dimension to a brick header. This unit has at itsleft side a joint simulated by a cut-out 4 of the same type as shown inFig. 2. At the right hand 2,094,688 r of the masonry units 50 is shown asimilar brick most course not less than thewidth of a simuheader 53 withthe mortar joint simulated by a cut-out 4 of the type shown in Fig. 2.Below this header 53 is shown a stretcher brick 54 with a vertical jointat its left simulated by a cut-out 4. The horizontal simulated joint isshown as carried through to meet the unit 50, thus sepmating the twovertical joints 4 by a portion of the base material of the element. Thecutouts :3 along the edge of the sheet are made in a manner similar tothat shown in Fig. 2. It will be apparent from this description and fromFig. 8, as well as from the assembly of units of the type shown-in Fig.8-as illustrated in Fig. 9, that variations of the simulation of masonrystructures may be accomplished within the scope of our invention and avariety of applications of the stepped form of end edge of the elementmay be made while obtaining-the advantages which have been moreparticularly set forth in connection with the simulation of brickwork.It is also apparent that by suitable design modifications f the elementshown in Fig. 8 may be made, such as by cutting the element along theline DD, whereby, in a manner similar to that described in connectionwith Figs. 4 and 5, complementary elements may be obtained with avariation of the stepped form of the end of the element to suitdifferent conditions.

While our invention has been described more particularly in connectionwith covering units-of so-called slate surfaced roofing material, it mayV shape of the edges of the elements of stepped or ness and watertightness; and while our invention includes modifications adaptable tosuch uses, nevertheless it is equally applicable to coverings'tosimulate interior masonry walls which therefore need not be water tight,thestepped form nevertheless providing the' inconspicuous joint and thecontinuity of the simulation of the masonry structure.

What is claimed as new is:

1. A covering sheet for laying on a surface in overlapping arrangementwith similar sheets comprising a base having at least a part of thesurface thereof demarked by at least one stripe upon the sheet and bycuts in the base extending.

transversely to the stripe into areas simulating bricks laid in aplurality of courses with mortar joints therebetween, the ends of saidsheet transverse to said stripe being in stepped form corresponding tothat of the joints of brickwork so that the cuts in the brick simulatingareas 'are avoided, the longitudinal edges of the stepped form joiningend edges of the stepped form being along the lines simulating the topedges of the bricks for all the courses of bricks except the topmostcourse simulated upon the sheet, said sheet having a longitudinal edgejoining the extension of the end edge of said topmost course with theend edge of that portion of the sheet intended to be overlapped andformed-along a line at a distance above the top edge of said toplatedmortar joint.

2. A covering sheet for laying upon the surface of a wall in overlappingarrangement with similar covering sheets which comprises a base ofimpervious material and having extending across the portion of the sheetto be exposed a plurality of parallel stripes and having cuts in thebase betweenthe stripes in staggered arrangement simulatively to demarkthe bricks and 'to simulate respectively the horizontal and the verticaljoints of brickwork laid in courses, the ends of the sheet being cut instepped form along said simulated joints, the end of the portion of thesheet to be overlapped being in stepped relation to the cuts simulatingthe vertical joints of the brickwork, the horizontal edge of said stepin the overlapped portion being on a line at a distance from the top ofthe topmost simulated course of bricks greater than the width of ahorizontal joint of the brickwork.

3. A covering sheet for laying upon the surface of a wall in overlappingarrangement with similar covering sheets which comprises a base ofimpervious material having at least one stripe,

upon the sheet parallel to and spaced from the edge of the sheet to beexposed and from any other similar stripes upon the'sheet distancesequal to the distances between horizontal joints of brickwork andseparating at least two sets of areas having a dimension transversely tothe stripes equal to the depth of bricks as laid in courses, said basehaving therein a set of.cut-outs for each course extending transverselyto the stripes and in staggered arrangement to each other in thesuccessive courses to demark with 4 said stripes and'with said exposededge individual bricks in the courses, said sheet'being cut insteppedform at its ends alonglines of the simulated joints, the verticalend edges of the simulated brick courses being made at the end edges ofthe end bricks of each course upon the sheet, the horizontal bottom edgeof the sheet being coincident with the bottom edge of the lowermostcourse of the simulated bricks, the horizontal edges of the stepped formof the ends of the ex- 1 posed portion of the sheet being coincidentwith the bottom edge of the simulated horizontal joints, the verticaledges of each of said simulated horizontal joints at the two ends of thesheet being' spaced apart a distance greater than the length of thecourses of bricks upon the sheet by an amount equal to the width of avertical brickwork joint, the ends of the portion of the sheet to beoverlapped being so formed in stepped relation and so placed inoffset'relation to the vertical and longitudinal end edges of theexposed portion and to the cut-outs therein that when upon said portionto be overlapped is lapped the portion to be exposed of a similar sheetso that its cut-outs continue the staggered relation of those of theoverlapped sheet said cut-outs do not behaving demarked thereon aplurality of courses of simulated masonry units with mortar jointstherebetween, said sheet having an end edge extending generallytransversely of the courses in offset form along the end edges ofthesimulated.

masonry units at said end of the sheet and along edges in line with thebottom line of the simulated longitudinal joints of the masonry andconnecting to the end edges or extensions thereof 5 of the masonry unitsin two adjacent courses.

5. A covering sheet which comprises a base having a stripethereonsimulating a longitudinal joint of masonry and having spaced along-saidstripe at either side thereof and positioned transl0lversely thereofcut-outs in the base simulating transverse jointsof the masonry, saidstripe and said cut-outs demarking simulated masonry units,

said sh'e'et having an end edge extending generally g transversely ofsaid stripe in ofi-set form along the end edges of the simulated masonryunits at the ends of the sheet and along edges in line with the bottomline of said simulated longitudinal joint and connecting to the endedges or extensions thereof of the masonry units in two adjacentcourses.

6. A covering sheet which comprises a base having a stripe thereonsimulating a longitudinal joint of masonry and having spaced along saidstripe at either side thereof and positioned transversely thereofcut-outs in the base simulating transverse joints of the masonry, saidstripe and 7 said cut-outs demarking simulated masonry units, said sheethaving an end edge extending generally transversely of said stripe inoffset form along the end edges of the simulated masonry units at theends of the sheet and along edges in line with the bottom line of saidsimulated longitudinal joint and connecting to the end edges orextensions thereof of the masonry units in two adjacent courses, saidend of the sheet being formed with successive edges thereof ofisetprogressively in the same direction longitudinally of the stripe.

7. A covering sheet which comprises a base having demarked thereon aplurality of courses 40 of simulated masonry units with mortar jointstherebetween, said sheet having an end edge extending generallytransversely of the courses in oifset form along the end edges of thesimulated masonry units at said end of the sheet and along edges inlinewith the bottom line of the simulated longitudinal joints of themasonry and connecting to said end edges of the masonry units, thedimension of the simulated longitudinal joint longitudinally thereofbeing greater than the lo'ngitudinal dimension of said course betweensaid end edges of the end units thereof by an amount equal to the widthof a transverse joint, the end of that portion of said longitudinaljoint which provides a longitudinal edge of an ofiset being in line withthe end of the end unit of the course above said joint.

8. A 'covering' sheet for laying upon a surface in overlappingarrangement with similar covering sheets which comprises a base havi'ngdemarked upon the portion thereof to be exposed in the overlappingarrangement a course of simulated masonry units, said sheet having anend edge extending generally transversely of the course, said end edgebeing formed with the portion thereof to be overlapped by a superimposedelementofiset with respect to the pbiffiloiilthereof to be exposed, saidend edge havingfajportion like-extending with said course to form theoffset and connecting said two transverse portions and positioned at adistance from the upper boundary of the simulated units in said coursegreater than the width of a longitudinal mortar joint.

9. A covering sheet for laying upon a surface in overlapping arrangementwith similar covering sheets which comprises a base having demarked uponthe portion to be exposed in the overlapping arrangement a course ofsimulated masonry units with transverse mortar joints therebetween, saidportion of the sheet having edges transverse to the course at the endsof the end masonry units of the course, sald sheet hav-- ing in theportion thereof to be overlapped by a superimposed sheet end edgesextending transversely of the course and respectively offset in relationto the adjacent transverse end of the course, said sheet at each endhaving edges generally like-extending with saidcourse to form theoffsets and connecting the respective adjacent transverse edges of theportion to be exposed and theportion to be overlapped, said edgesgenerally like-extending with the course being at a distance from theline of the upper boundary of the units .of said course greaterthan thewidth of a longitudinal mortar joint, the dimension of said overlappedportion of the sheetwhich is like-extending with said courseubeinggreater than the course-wise dimension of said course by an amount equalto the width of a transverse mortar joint.

